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Timing Chain > < In-vehicle Repair|Valves

Mondeo 2001 (10.2000-02.2007)

Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) - Camshafts Mondeo 2001 (10/2000-02/2007)
In-vehicle Repair

Special Tool(s)

Flange Holding Wrench, Universal

205-072 (15-030A)

Timing Plate, Camshaft Alignment

303-376 (21-162B)

Remover/Installer, Spark Plug

303-499 (21-202)

Timing Peg, Crankshaft TDC

303-507 (21-210)

Pliers, Valve Stem Oil Seal

303-508 (21-211)
General Equipment
M6 x 18 mm bolt
M6 x 25 mm bolt
Materials
Name
Specification
Silicone sealant
WSE-M4G323-A6 
Sealant 3M 2510
ESS-M11P24-A1 
Hypoid oil
SQM-2C9002-AA 

Removal
  1. Detach the positive crankcase ventilation hose (PCV) and the vacuum hose from the engine upper cover.

  1. Remove the engine upper cover.
  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Disconnect the camshaft position (CMP) sensor electrical connector.

  1. Detach the engine wiring harness electrical connector from the valve cover.

  1. Detach the PCV hose from the valve cover.

  1. Remove the engine upper cover retaining brackets.

  1. Using the special tool, disconnect the spark plug electrical connectors.

  1. Using the special tool, remove the spark plugs.

  1. Remove the valve cover.
  1. Remove the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the engine front cover lower blanking plug.

  1. Remove the cylinder block lower blanking plug and install the special tool.
  1. Lower the vehicle.

  1. Remove the engine front cover upper blanking plug.

  1. CAUTION:
    CAUTION:To detension the timing chain, make sure the timing chain tensioner ratchet is in the released position.
    Detension the timing chain.
    1. Using a suitable screwdriver, unlock the timing chain tensioner ratchet.
    1. Carefully turn the exhaust camshaft by the hexagon in the normal direction of rotation, to detension the timing chain tensioner.
    1. Install a suitable M6 x 18 mm bolt through the blanking plug to secure the timing chain guide in the detensioned position.

  1. CAUTION:
    CAUTION:Hold the camshaft by the hexagon with an open-ended wrench to stop it from turning.
    NOTE:
    NOTE:Using a suitable piece of wire, prevent the timing chain and the sprocket from dropping into the timing case.
    Loosen the camshaft sprockets retaining bolts.
    • Detach the exhaust camshaft sprocket together with the timing chain from the exhaust camshaft.

  1. CAUTION:
    CAUTION:Keep the camshaft bearing caps, the camshafts and the camshaft sprockets in order for installation.
    NOTE:
    NOTE:Working in several stages, release each camshaft bearing cap retaining bolt two turns at a time.
    Remove the camshaft bearing caps in the sequence shown .
  1. NOTE:
    NOTE:Using a suitable piece of wire, prevent the timing chain and the sprocket from dropping into the timing case.
    Detach the intake camshaft sprocket from the intake camshaft.

Installation
  1. Turn the engine against its normal direction until piston No. 1 is approximately 45 degrees before top dead center (TDC).
  1. NOTE:
    NOTE:Do not tighten the camshaft sprocket retaining bolt at this stage.
    Attach the intake camshaft sprocket together with the timing chain to the intake camshaft and insert the intake camshaft.

  1. CAUTION:
    CAUTION:Install the camshafts approximately at valve overlap position cylinder No. 4.
    CAUTION:
    CAUTION:Install the camshafts and bearing caps in their original location.
    Install the camshafts.
    • Working in several stages, evenly tighten the camshaft bearing cap bolts in the sequence shown, one half turn at a time.
    • Tighten the bolts in two stages:
    • Stage 1: 7 Nm.
    • Stage 2: 16 Nm.

  1. NOTE:
    NOTE:Do not tighten the camshaft sprocket retaining bolt at this stage.
    Attach the exhaust camshaft sprocket together with the timing chain to the exhaust camshaft.

  1. Install the special tool.
  1. Coat the engine front cover upper blanking plug with sealant.

  1. Tension the timing chain.
    • Remove the timing chain guide securing bolt and install the engine front cover upper blanking plug.
  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine until piston No. 1 is at TDC.

  1. NOTE:
    NOTE:Hold the camshafts by the hexagon with an open-ended wrench to stop them from rotating.
    Tighten the camshaft sprocket retaining bolts.

  1. Remove the special tool.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the special tool from the cylinder block.
  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine two revolutions.

  1. Install the special tool.
  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine until piston No. 1 is at TDC.

  1. CAUTION:
    CAUTION:Only tighten the crankshaft pulley securing bolt finger tight.
    NOTE:
    NOTE:If it is not possible to install the crankshaft pulley securing bolt, correct the valve timing.
    Using a M6 x 18 mm bolt, check the position of the crankshaft pulley.
  1. Lower the vehicle.

  1. NOTE:
    NOTE:If it is not possible to install the special tool, correct the valve timing.
    Using the special tool, check the position of the camshafts.

  1. Remove the special tool.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the crankshaft pulley securing bolt.

  1. Remove the special tool.

  1. Install the cylinder block lower blanking plug.
  1. Coat the engine front cover lower blanking plug with sealant.

  1. Install the engine front cover lower blanking plug.
  1. Install the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.

  1. Apply a small bead of sealer to the areas as shown.

  1. NOTE:
    NOTE:Install a new valve cover gasket if necessary.
    Install the valve cover.
    • Tighten the bolts in the sequence shown.

  1. Using the special tool, install the spark plugs.

  1. Using the special tool, connect the spark plug electrical connectors.

  1. Install the engine upper cover retaining brackets.

  1. Attach the PCV hose to the valve cover.

  1. Connect the CMP sensor electrical connector.

  1. Attach the engine wiring harness electrical connector to the valve cover.
  1. Connect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Install the engine upper cover.

  1. Attach the PCV hose and the vacuum hose to the engine upper cover.
  1. Initialize the door window motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

Timing Chain > < In-vehicle Repair|Valves